Transcript Document

Design for Commonality
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Team
Project Team Members:
Brisia Roberts
Mike Howie
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Commonality Definitions
 1. A quality that applies to materiel or systems: (a)
possessing like and interchangeable characteristics
enabling each to be utilized, or operated and maintained
by personnel trained on the others without additional
specialized training; (b) having interchangeable repair
parts and/or components; (c) applying to consumable
items interchangeably equivalent without adjustment
 2. Pertaining to equipment or systems that have the
quality of one entity possessing like and interchangeable
parts with another equipment or system entity.
 Pertaining to system design in which a given part can be
used in more than one place in the system, i.e.,
subsystems and components have parts in common.
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Commonality at Ford
What is a CBP and what is the CBP Process?
Strategy
Annual evaluation
and adjustment
Execution on
Programs
Technology
Supply Base
Value Chain/
Material Flow
Targets
Tracking
Action Plan
Commodity Business Plan
• A 5-Year Strategy, Targets, and Action Plan setting the Technology, Supply Base, and Value
Chain/Material Flow course for a commodity.
• An executable plan that analysis shows can
achieve the business needs: Quality, Cost,
Customer Satisfaction, Timing
• Provides a blueprint to coordinate functional
groups and evaluate downstream decisions.
• Includes a specific, time-bound upstream program
migration plan – enables GPDS pre-program.
CBP Process
Key functions come together and
manage the commodity as a team:
• Develop and gain approval for initial
business plan
• Execute the business plan per the
action plan – ongoing management
of the commodity.
• Track progress of implementation
on programs.
• Re-evaluate and adjust the plan
annually
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Commonality Encompasses:
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Specifications
Test procedures
Processes
Components
Technologies
Platforms
Goals
BOMs
Methods
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Commonality Benefits
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Reduced cost savings in three areas:
Manufacturing
Assembly
Inventory
Reduced investment in product development
Reduced product complexity
Common specifications
Increase economies of scale
Common BOMs
Increased product variety through mixing and
matching
 Reduced lead-in time for production design
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Commonality Benefits
 Improved ability to upgrade products
 Better learning across products
 Acceleration of testing and Certification of
products
 Ease of designing new market niches
 Reduction in the number of different
production processes
 Avoid launch spikes
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Commonality Disadvantages
 Brand identity can be compromised
 Internal conflict over
distinctiveness/commonality (marketing
versus engineering)
 Difficult to implement
 It can impose severe constraints
 Increased technical difficulties
 Stagnation of long term innovation
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Commonality Enablers
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Cultural change
Upper management commitment
Market analysis
Technology
Investment
Quality products
Planning across organizations
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Commonality Enablers
 Capable suppliers
 Effective management of product variety
 Minimization of non-value added variations
within a product
 Control the commonality of specified
products
 Purchasing engaging from beginning to end
 Creation of cross commodity teams
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Cross Commodity team structure
 A small business with team members:
 Owners of cost, quality, weight, supplier selection, and
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technology for their commodity
Developers of a migration plan to support the cycle plan
Integrators of brand attributes responsible for application to
their commodity
Designers of value proposition recommendations for their
commodity aligned with ‘Ford stands for Value’
Creators of commodity plans that encompass SCT, TVM,
MCR, NDPC, EMSI, etc. into one cohesive plan to achieve
targets
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Commonality Case Study for Audio
Components at Ford Motor Company
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Audio Components Case Study
 Commonality is a term used more and more in daily
business decisions.
 Ford is currently implementing commonality in all radios.
The pictures below show how you can achieve commonality
but maintaining different styling.
U377 Center Stack
C170 Center Stack
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Traditional Audio Head Units
Current state:
• In the audio group we had minimal Volume Leverage
Realization. The suppliers used to deliver components
that optimize their internal volumes across radios, but
savings did not flow through to Ford.
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Traditional Audio Head Units
 In the past Ford did not have a common strategy to
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design audio head units
Each vehicle platform had their own communication
protocol.
Each vehicle platform had their own mounting strategy
Each vehicle platform had their own styling cues
Each vehicle platform had their own HMI strategy
Each vehicle platform had their own mechanism
Each vehicle platform had their own lighting strategy
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Current Escape Platform Radios
 The Escape program currently has six different radios
Content
Radio Type
Premium
Premium
Premium
Premium
Audiophile
Audiophile
Media Type
CDX6
SCD
CDX6
CDX6
CDX6
Navigation
Tuner Frequency
North America
North America
GCC
GCC
North America
North America
Communication
Protocol
ACP
ACP
ACP
ACP
ACP
MSCAN
Button Layout
Unique
Unique
Unique
Unique
Unique
Unique
MY
2006-2007
2006-2007
2006-2007
2006-2007
2006-2007
2006-2007
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Current Escape Radio Pictures
CDX6 Audiophile
Single CD Premium
Navigation Head Unit
CDX6 Premium
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New MY09 Escape/Focus Platforms Radios
 The Escape platform has Three Radios with common Button
Layout, common mechanism, common communication
protocol, common HMI, common lighting, common tuner,
common display, and common mounting scheme.
Content
Communication
Button Layout
Radio Type
Media Type Tuner Frequency Protocol
MY
Premium/Audiophile CDX6
North America
MSCAN
Common
2009
Premium
SCD
North America
ACP
Common
2009
Audiophile
Navigation North America
MSCAN
Unique
2009
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Audio commonality includes the following
components:
Center Stack Multimedia Components
FDM
ACM
C170 FCIM
U377 FCIM
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Audio commonality includes the following
components:
 Common B-side design of FCIM between C170/U377, which allows for
studio flexibility of A-surface, without additional large investment cost
to tool up new radios for each program.
Escape Button Set
Focus Button Set
Common Components
• PCB
• Back cover plate
• MSCAN Interface
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What is common in the new radios?
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One common display for Escape and Focus platforms
One common chassis with common mechanisms
One common attachment scheme
One common mother board for the buttons
One common tuner
One common chip set
One common HMI
One common lighting strategy
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What is different in the new radios?
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Unique styling design
Unique antenna system
Unique equalization
Unique Center finish panel
Unique Climate Control system
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Customer benefits
 Lower development costs
 Lower piece cost
 Bold new Cockpit Interior
design strategy with lower
investments.
 Lower piece cost for
combined volumes
Escape Center Stack
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Customer benefits
•Great fit/finish
•Zero deflection
•Common hardware but
unique look between
Escape and Focus.
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Commonality Implementation at Ford
 U377 1PP, August 2006, Job#1, January 2007
 C170 1PP, March 2007, Job#1, August 2007
 2009/2010 MY programs to follow with Next Generation
Center stack base on groundwork of U377/C170
- MY 2009/2009.5
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D385
D471
P415
CD338
CD378
S197
D472
- MY 2010
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U387
U388
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Heuristics for Commonality
 Common componentry isn’t necessarily optimized
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componentry
Scaling a part doesn’t always mean the validation is
equally scaled
There is a difference between cheap parts and
inexpensive good parts
Common processes doesn’t = common risk
Common processes doesn’t mean common parts
Common processes doesn’t mean common requirements
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